Onan MEP-003A User manual

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5-6115-585-34

ARMY

TECHNICAL

MANUAL

NAVY

PUBLICATION

AIR

FORCE

TECHNICAL

ORDER

MARINE

CORPS

TECHNICAL

MANUAL

TM5-6115-585-34

NAVFAC

8-262-12

35C2-3-455-2

05684C

TECHNICAL

MANUAL

INTERMEDIATE

(

FIELD

) (

DIRECT

AND

GENERAL

SUPPORT

)

AND

DEPOT

LEVEL

MAINTENANCE

MANUAL

GENERATOR

SET

DIESEL

ENGINE

DRIVEN

TACTICAL

SKID

MTD

10KW

PHASE

WIRE

PHASE

WIRE

PHASE

WIRE

120

120/240

AND

120/208

VOLTS

DOD

MODEL

CLASS

HERTZ

NSN

MEP

003A

UTILITY

6115-00-465-1030

LIBRARY

PIDERMAN

PUBLIC

DOCUMENTS

REFEREXCE

DEPARTMENT

SEP

1989

This

copy

reprint

which

includes

current

pages

from

Changes

thru

VIVERSITY

VIRGINIA

UNIVERSITY

VIRGINIA

LIBRARY

X004816008

PUBLISHED

UNDER

THE

AUTHORITY OF THE

DEPARTMENTS

THE

ARMY

AIR

FORCE

NAVY

AND

HEADQUARTERS

U.S.

MARINE

CORPS

JULY

1977

89-571

-P

TM5-6115-585-34

NAVFAC

8-262-12

35C2-3-455-2

05684C

WARNING

All

specific

cautions

and

warnings

contained

this

manual

shall

strictly

adhered

Otherwise

severe

injury

death

and

damage

the

equipment

may

result

HIGH

VOLTAGE

produced

when

this

Generator

Set

operation

DEATH

or severe

burns

may

result

personnel

fail

observe

safety

precautions

not

operate

this

Generator

Set

until

the

ground

terminal

stud

has

been

connected

suitable

ground

Disconnect

the

battery

ground

cable

before

removing

and

installing

components

the

engine

the

electrical

control

panel

system

Remove

all

rings

watches

and

other

jewelry

when

performing

maintenance on

this

equipment

Loose

fitting

clothing

should

secured

prevent

catching

moving

parts

not

attempt

service

otherwise

make

any

adjustments

connections

recon

nections

wires

cables

until

Generator

Set

shut

down

and

completely

energized

DANGEROUS

GASES

Batteries

generate

explosive

gas

during

charging

therefore

utilize

extreme

caution

not

smoke

use

open

flame

the

vicinity

the

Generator

Set

when

servicing

batteries

Exhaust

discharge

contains

noxious

and

deadly

fumes

not

operate

Generator

Sets

enclosed

areas

unless

exhaust

discharge

properly

vented

the

outside

avoid

sparking

between

filler

nozzle

and

fuel

tank

always

maintain

metal

contact

between

filler

nozzle

and

fuel

tank

when

filling

fuel

tank

not

smoke

use

open

flame

the

vicinity

the

Generator

Set

while

fueling

LIQUIDS

UNDER

HIGH

PRESSURE

are

generated

result

operation

the

Generator

Set

not

expose any

part

of the

body

high

pressure

leak

the

fuel

injection

system

WARNING

Clean

parts

well

ventilated

area

Avoid

inhalation

solvent

fumes

and

pro

longed

exposure

skin

cleaning

solvent

Wash

exposed

skin

thoroughly

Dry

cleaning

solvent

(

Fed

Spec

680

)

used

clean parts

potentially

dangerous

personnel

and

property

not

use

near

open

flame

excessive

heat

Flash

point

solvent

100

138

(

° C .

)

WARNING

conditions

require

fuel

tank

repairs

welding

other

methods

involving

heat

flame

take

care

assure

that

all

fumes

are

purged

from

the

tank

fill

tank

with

water

before

commencing

the

repair

possible

tank

should

filled

with

water

prior

welding

after

being

thoroughly

purged

fumes

Applying

heat

flame

fuel

tank

containing

residue

may

result

violent

explosion

causing

death

injury

maintenance

personnel

NOISE

Operating

level

this

generator

can

cause

hearing

damage

Ear

protectors

recommended

the

medical

worn

when

working

near

this

set

DEPARTMENT

THE

ARMY

TECHNICAL

MANUAL

5-6115-585-34

DEPARTMENT

OF THE

NAVY

PUBLICATION

DEPARTMENT

OF THE

AIR

FORCE

TECHNICAL

ORDER

MARINE

CORPS

TECHNICAL

MANUAL

NAVFAC

8-623-34

35C2-3-455-2

05684C

05685B

CHANGE

HEADQUARTERS

DEPARTMENTS

THE

ARMY

NAVY

AIR

FORCE

AND

USMC

WASHINGTON

D.C.

December

1986

No.

Intermediate

(

Field

)

(

Direct

and

General

Support

)

and

Depot

Level

Maintenance

Manual

GENERATOR

SET

DIESEL ENGINE DRIVEN

TACTICAL

SKID

MTD

PHASE

WIRE

PHASE

WIRE

PHASE

WIRE

120

120/240

AND 120/208 VOLTS

DOD

MODEL

CLASS

HERTZ

NSN

MEP

003A

MEP

112A

UTILITY

400

6115-00-465-1030

6115-00-465-1027

5-6115-585-34

NAVFAC

8-623-34

35C2-3-455-2

05684C

05685B

July

1977

changed

follows

Remove

and

insert

pages

indicated

below

New

changed

text

material

indicated

vertical

bar

the

margin

illustration

change

indicated

miniature

pointing

hand

Remove

pages

Insert

pages

1-3 and 1-4

6-1

and 6-2

6-11

and

6-12

6-19

and

6-20

7-1

and 7-2

7-10.1

and

7-10.2

7-13

and

7-14

7-37

and

7-38

1-3

and

1-4

6-1 and 6-2

6-11

and

6-12

6-19

and

6-20

7-1 and

7-2

7-10.1

and

7-10.2

7-13

and

7-14

7-37

and

7-38

Retain this

sheet

front

manual

for

reference

purposes

5-6115-585-34

NAVFAC

8-623-34

35C2-3-455-2

05684C

05685B

Order

the

Secretaries

the

Army

the

Navy

and

the

Air

Force

E. C.

MEYER

General

United

States

Army

Chief

Staff

Official

PENNINGTON

Major

General

United

States

Army

The

Adjutant

General

D. G.

ISELIN

Rear

Admiral

CEC

Navy

Commander

Naval Facilities

Engineering

Command

Official

LEW

ALLEN

. ,

General

USAF

Chief

Staff

VAN

CRAWFORD

. ,

Colonel

USAF

Director

Administration

H. A.

HATCH

Major

General

USMC

Deputy

Chief

Staff for

Installations

and

Logistics

DISTRIBUTION

Active

Army

distributed

accordance

with

Form

12-25D

Direct and

General

Support

Maintenance

Requirements

for

Generator

Sets

Engine

Driven

400

Marine

Corps

MARCORPS

CODES

AGB

5-6116-686-34

NAVFAC

8-623-84

85V2-3-456-2

06884C

CHANGE

DEPARTMENT

THE

ARMY

AIR

FORCE

AND

USMC

WASHINGTON

August

1979

No.

INTERMEDIATE

(

FIELD

)

(

DIRECT

AND

GENERAL

SUPPORT

)

AND

DEPOT

LEVEL

MAINTENANCE

MANUAL

GENERATOR

SET

DIESEL

ENGINE

DRIVEN

TACTICAL

SKID

MTD

10KW

PHASE

- 2

WIRE

PHASE

WIRE

PHASE

- 4

WIRE

120

120/240

AND

120/208

VOLTS

DOD

MODEL

CLASS

HERTZ

NSN

MEP

003A

UTILITY

6115-00-465-1030

5-6115-586-34

NAVFAC

8-623-34

35C2-3-455-2

05684C

July 1977

changed

as follows

Remove

and

insert

pages

indicated

below

Remove

pages

Insert

pages

thru

1.9

1-10

6-1

thru

6-8

6-13

and

6-14

INDEX

thru

1.9

1-10

6-1

thru

6-8

6-13

and

6.14

INDEX

New

changed

text

material

indicated

vertical

bar

the

margin

illustration

change

indi

cated

by a

miniature

pointing

hand

Retain

these

sheets

front

manual

for

reference

purpose

6-6116-685-34

NAVFAC

8-623-34

35V2-3-455-2

05684C

Order

the

Secretaries

the

Army

the

Air

Force

and

the

Marines

E. C.

MEYER

General

United

States

Army

Chief

Staff

Official

PENNINGTON

Major

General

United

States

Army

The

Adjutant

General

DAVID

JONES

General

USAF

Chief

Staff

Official

Jack

BENSON

Colonel

USAF

Director

Adminsitration

WALLS

Acting

Deputy

Chief

Staff

for

Installations

Logistics

DISTRIBUTION

distributed

accordance

with

Form

12-25D

Direct

and

General

Support

Maintenance

Requirements

for

Generator

Sets

Engine

Driven

DEPARTMENT

THE

ARMY

TECHNICAL

MANUAL

TM5-6115-585-34

DEPARTMENT

THE

NAVY

PUBLICATION

NAVFAC

8-623-34

DEPARTMENT

THE

AIR

FORCE

TECHNICAL

ORDER

35C2-3-455-2

MARINE

CORPS

TECHNICAL

MANUAL

05684C

05685B

HEADQUARTERS

DEPARTMENTS

THE

ARMY

NAVY

AIR

FORCE

USMC

WASHINGTON

D.C.

JULY

1977

INTERMEDIATE

(

FIELD

)

(

DIRECT

AND

GENERAL

SUPPORT

)

AND

DEPOT

LEVEL

MAINTENANCE

MANUAL

GENERATOR

SET

DIESEL

ENGINE

DRIVEN

TACTICAL

SKID

MTD

10KW

PHASE

WIRE

PHASE

WIRE

PHASE

WIRE

120

120/240

AND

120/208

VOLTS

DOD

MODEL

CLASS

HERTZ

NSN

MEP

003A

UTILITY

6115-00-465-1030

MEP

112A

UTILITY

400

6115-00-465-1027

TABLE

CONTENTS

Page

LIST

EFFECTIVE

PAGES

LIST

ILLUSTRATIONS

LIST

TABLES

INTRODUCTION

1-1

CHAPTER

Section

GENERAL

1-1

1-2

1-3

1-4

1-5

Scope

Limited

Applicability

Maintenance

Forms

and

Records

Reporting

Errors

Levels

Maintenance

Accomplishment

1-1

Section

DESCRIPTION

AND

TABULATED

DATA

1-1

1-6

1-7

Description

Tabulated

Data

1-1

CHAPTER

GENERAL

MAINTENANCE

INSTRUCTIONS

2-1

Section

REPAIR

PARTS

SPECIAL

TOOLS

TEST

MEASUREMENT

AND

DIAGNOSIC

EQUIPMENT

(

TMDE

AND

SUPPORT

EQUIPMENT

2-1

2-2

2-3

Repair

Parts

Tools

and

Equipment

Fabricated Tools

and

Equipment

2-1

Section

TROUBLESHOOTING

2-5

2-4

2-5

General

Malfunctions

Not

Corrected

Use

the

Troubleshooting

Table

2-5

Change

TM5-6115-585-34

NAVFAC

8-262-12

35C2-3-455-2

05684C

05685B

TABLE

CONTENTS

(

CONT

)

Page

Section

GENERAL

MAINTENANCE

2-12

2-6

2-7

General

Maintenance

General

Maintenance

Procedures

2-12

Section

REMOVAL

AND

INSTALLATION

MAJOR

COMPONENTS

2-12

2-8

Control

Cubicle

2-9

Engine

Assembly

2-10

Generator

Assembly

2-12

2-16

CHAPTER

MAINTENANCE

COOLING

SYSTEM

3-1

Section

DESCRIPTION

AND

FUNCTION

3-1

General

3-1

Section

MAINTENANCE

3-1

3-2

3-3

Engine

Cooling

System

High

Temperature

Cut

Out

Switch

3-1

CHAPTER

MAINTENANCE

OF FUEL

SYSTEM

4-1

Section

DESCRIPTION

AND

FUNCTION

4-1

General

4-1

Section

MAINTENANCE

FUEL TANK

4-1

4-2

Fuel

Tank

4-1

CHAPTER

MAINTENANCE

STARTING

SYSTEM

5-1

Section

DESCRIPTION

AND

FUNCTION

5-1

General

5-1

Section

MAINTENANCE

5-1

5-2

Starter

Assembly

5-1

CHAPTER

MAINTENANCE

CONTROL

SYSTEM

6-1

Section

DESCRIPTION

AND

FUNCTION

6-1

6-2

6-3

Control

System

Instrumentation

System

Voltage

Regulator

6-1

Section

MAINTENANCE

6-1

6-4

6-5

6-6

6-7

6-8

6-9

Control

Cubicle

Generator

Set

Wiring

Harness

Voltage

Regulator

Output

Control

Box

Wiring

Harness

Output

Control

Box

Assembly

...

Output

Control

Box

(

Internal

Components

)

6-1

6-8

6-9

5-6115-585-34

NAVFAC

8-623-34

35C2-3-455-2

05684C

05685B

TABLE

CONTENTS

(

CONT

)

Page

CHAPTER

MAINTENANCE

ENGINE

7-1

Section

DESCRIPTION

AND

FUNCTION

7-1

General

7-1

Section

ENGINE

EXTERNAL

ASSEMBLY

7-1

7-2

7-3

7-4

7-5

7-6

7-7

7-8

Fuel

Lines

External

Governor

Parts

and

Speed

Control

Assembly

Flywheel

and

Ring

Gear

Assembly

Flywheel

Housing

Oil

Cooler

Blower

Wheel

Assembly

Battery

Charge

Alternator

7-1

7-5

7-6

7-8

Section

III

ENGINE

INTERNAL

ASSEMBLIES

7-8.1

Engine

Compression

Test

7-9

Cylinder

Head

7-10

Piston

and

Connecting

Rod

7-11

Oil

Pump

7-12

Oil Filter

Adapter

Assembly

7-13

Oil

Pass

Valve

7-14

Gear

Cover

Assembly

7-15

Governor

Cup

7-16

Camshaft

Assembly

and

Tappets

7-17

Crankshaft

and

Main

Block

Bearings

7-18

Fuel

Injection

Pump

7-19

Cylinder

Block

7-20

Fuel

Injector

7-9

7-10.1

7-13

7-19

7-21

7-25

7-27

7-30

7-41

CHAPTER

MAINTENANCE

GENERATOR

ASSEMBLY

8-1

Section

DESCRIPTION

AND

FUNCTION

8-1

General

8-1

Section

MAINTENANCE

8-1

8-2

Generator Maintenance

8-1

CHAPTER

GENERATOR

SET

TEST

AND

INSPECTION

AFTER

REPAIR

OVERHAUL

9-1

Section

GENERAL

REQUIREMENTS

9-1

General

Information

9-1

Section

INSPECTION

9-1

9-2

9-3

General

Engine

Cooling

System

Wiring

Harnesses

9-1

9-4

Section

III

OPERATIONAL

TESTS

9-1

Generator and

Generator

Control

Circuitry

Engine

Control

Circuitry

REFERENCE

9-5

9-6

9-1

APPENDLX

INDEX

Change

iii

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